HK1166845B - Manifold assembly for distributing a fluid to a heat exchanger - Google Patents

Description

Manifold assembly for distributing fluid to a heat exchanger

The applicant hereby claims priority from U.S. provisional patent application No.61/160,025 filed 3/13/2009, the disclosure of which is incorporated herein by reference, in accordance with 35 u.s.c. § 119 (e).

Technical Field

The present disclosure relates generally to heat exchanger systems and more particularly to manifold assemblies for heat exchanger systems.

Background

Heat exchange systems, such as parallel flow heat exchanger systems ("parallel flow systems"), are used in condenser and evaporator applications for a variety of products and system designs and configurations. Typically, parallel flow systems include a heat exchanger, such as an evaporator, having a plurality of parallel passages fluidly coupled between a plurality of channels in an inlet manifold assembly and a plurality of channels in an outlet manifold assembly. In operation, coolant (sometimes referred to as refrigerant) is distributed into and flows through the passages of the heat exchanger in a flow direction that is substantially perpendicular to the direction of the inlet and outlet manifold assemblies. As the air flow passes through the heat exchanger, heat is exchanged between the air flow and the coolant fluid.

Uneven distribution of coolant in heat exchanger systems, particularly in parallel flow systems, due to flow design is well known in the art. Uneven distribution of coolant may occur due to uneven air flow distribution over external heat transfer surfaces, improper heat exchanger orientation or poor manifold and distribution system design due to differences in flow impedance and pressure drop created within and across the heat exchanger passages. For example, in parallel flow systems, uneven distribution may result due in part to the varying lengths of internal coolant distribution paths within the inlet and outlet manifold assemblies, which may result in varying pressure drops across the passages.

In the prior art, the channels in the manifold assembly have been adjusted to reduce the adverse effects of uneven coolant distribution. For example, in those situations where the air flow distribution through the heat exchanger is not uniform, the flow profile in each channel may be adjusted so that more coolant flows through the passages in the heat exchanger that are exposed to a higher percentage of the air flow. However, manufacturing problems may arise where the manifold assembly includes channels having different tailored flow profiles. For example, a first channel having a first flow profile may appear externally similar to a second channel having a second flow profile different from the first flow profile. This external similarity can result in improper placement of the different channels in the manifold assembly, resulting in improper coolant flow characteristics.

Disclosure of Invention

According to one aspect of the present invention, a manifold assembly for distributing a fluid to a heat exchanger is provided that includes a plurality of channels and a manifold. The plurality of channels includes one or more first channels and one or more second channels. Each first channel has a first flow profile and a manifold end with a first cross-sectional geometry. Each second channel has a second flow profile and a manifold end with a second cross-sectional geometry. The first cross-sectional geometry is different from the second cross-sectional geometry. The manifold has an internal cavity, an inlet port, one or more first channel ports and one or more second channel ports. Each first channel port is configured to mate with a manifold end of a first channel. Each second channel port is configured to mate with a manifold end of a second channel.

In accordance with another aspect of the present invention, a method for manufacturing a manifold assembly for distributing fluid to a heat exchanger is provided. The method comprises the following steps: a) providing a manifold having: an inner cavity; one or more first channel ports, each first channel port having a first port geometry; and one or more second channel ports, each second channel port having a second port geometry, the second port geometry being different from the first port geometry; b) providing one or more first channels, each first channel having a manifold end and a chamber end (cell end), and each first channel having a first flow profile, wherein the manifold end of each first channel mates with each first channel port; c) providing one or more second channels, each second channel having a manifold end and a chamber end, and each second channel having a second flow profile, wherein the manifold end of each second channel mates with each second channel port; and, d) mating the manifold end of each first channel with one of the first channel ports disposed within the manifold; and mating the manifold end of each second channel with one of the second channel ports disposed within the manifold to fluidly couple the manifold lumen to the first channel and the second channel.

Drawings

FIG. 1 is a schematic diagram of an embodiment of a heat exchanger system.

FIG. 2 is a schematic view of an embodiment of a manifold assembly.

FIG. 3 is a schematic view of one embodiment of a first channel.

FIG. 4 is a schematic view of one embodiment of a second channel.

Detailed Description

FIG. 1 is a schematic diagram of one embodiment of a heat exchanger system 100 for exchanging heat between an internally flowing fluid (e.g., a coolant or refrigerant) and an externally flowing fluid (e.g., air). The heat exchanger system 100 includes at least one manifold assembly 10 and a heat exchanger 12 having at least one chamber. It should be noted that in some embodiments, the different chambers of heat exchanger 12 may be divided into physically separate units, as is known in the art (not shown).

FIG. 2 is a schematic view of one embodiment of a manifold assembly 10 for distributing fluid to one or more chambers of a heat exchanger 12. The manifold assembly 10 includes a manifold 14 and a plurality of tubular passages (also referred to as "counterbores"). The plurality of tubular passages includes one or more first passages 16 and one or more second passages 18.

The manifold 14 includes an inner cavity 20 extending between a first end 22 and a second end 24, one or more first channel ports 26, one or more second channel ports 28, and an inlet port 30. The ports are fluidly coupled to the inner cavity 20. Each first channel port 26 has a geometry that mates with the cross-sectional geometry of the manifold end of the first channel 16, as will be described below. Each second channel port 28 has a geometry that mates with the cross-sectional geometry of the manifold end of the second channel 18, as will be described below. The geometry of the first channel port 26 is different from the geometry of the second channel port 28.

Referring now to fig. 3, each first channel 16 has a central section 32 extending between a manifold end 34 and a chamber end 36 and an internal passage 38. An internal passageway extends all the way through the first channel 16 between the manifold end 34 and the chamber end 36 to allow fluid to pass through the channel. The manifold end 34 has a cross-sectional geometry and the chamber end 36 has a cross-sectional geometry. In some embodiments, the cross-sectional geometry of the chamber end 36 is different than the cross-sectional geometry of the manifold end 34. In the example shown in fig. 3, the manifold end 34, the central section 32, and the chamber end 36 have circular cross-sections. The diameter of the manifold end 34 is equal to the diameter of the central section 32 and the chamber end 36 has a smaller diameter than both. The aforementioned cross-sectional geometry is not limited to circles and the relative diameters may vary to suit the current application. In some embodiments, a first shoulder 40 or weld bead is circumferentially disposed about the first channel 16.

In most embodiments, the first channel 16 is characterized by a pressure differential between the manifold end 34 and the chamber end 36. The pressure differential is greater than the line losses that are typically caused by friction or other factors such as the line configuration. This feature may be a change in cross-sectional area (e.g., constriction) of the first passageway 16 or it may be an element operable to block flow within the passageway 38. A cup-shaped flow restrictor 42 with an orifice 44 through which flow must pass is an example of a feature that may be placed within the passageway 38 of the first channel 16 to block flow to create a pressure differential to the flow through the first channel 16. The present invention is not limited to any particular type of feature. This characteristic is selectively selected to create a particular pressure differential across the first passage 16 under expected operating conditions, which may be generally referred to as a first flow profile.

Referring now to fig. 4, the second channel 18 has a central section 46 extending between a manifold end 48 and a chamber end 50, and an internal passage 52. The internal passageway 52 extends all the way through the second channel 18 between the manifold end 48 and the chamber end 50 to allow fluid to pass through the channel. The manifold end 48 has a cross-sectional geometry and the chamber end 50 has a cross-sectional geometry. In some embodiments, the cross-sectional geometry of the chamber end 50 is different than the cross-sectional geometry of the manifold end 48. In the example shown in fig. 4, the manifold end 48, the central section 46, and the chamber end 50 have circular cross-sections. The manifold end 48 has a diameter that is smaller than the diameters of the central section 46 and the chamber end 50, and the chamber end 50 has a diameter that is smaller than the central section 46. The aforementioned cross-sectional geometry is not limited to circles and the relative diameters may vary to suit the current application. In some embodiments, a first shoulder 54 or weld bead is circumferentially disposed about the second channel 18.

The cross-sectional geometry of the manifold end 48 of the second channel 18 is different than the cross-sectional geometry of the manifold end 34 of the first channel 16. Thus, the manifold end 48 of each second channel 18 that mates with a second channel port 28 disposed in the manifold 14 will only mate with the second channel port 28 and will not mate with the first channel port 26 disposed within the manifold 14. The first channel port 26 is configured to mate with a manifold end 34 of the first channel 16. The term "mate" is used herein to describe a connection between a manifold end of a channel and a manifold port, where the end physically mates with the port (e.g., one receivable within the other) such that the fit between the two allows for sealing of a leak between them.

In most embodiments, the second channel 18 is characterized by a pressure differential between the manifold end 48 and the chamber end 50. This feature may be a change in cross-sectional area (e.g., constriction) of the first channel 16 or it may be an element operable to block flow within the passageway 52. A cup-shaped flow restrictor 56 with an orifice 58 through which flow must pass is an example of a feature that may be placed within the passageway 52 of the first channel 16 to block flow to create a pressure differential to the flow through the first channel 16. The present invention is not limited to any particular type of feature. This characteristic is selectively selected to create a particular pressure differential across the second passage 18 under expected operating conditions, which may be generally referred to as a second flow profile.

Assembling the first and second channels 16, 18 onto the manifold 14 requires that the intended channels mate with the intended channel ports within the manifold 14. Correctly positioning the channels relative to the manifold 14 ensures that the desired channel flow profile matches the desired area within the heat exchanger 12. In the prior art, it is possible to place the first and second channels 16, 18 in incorrect positions because the first and second channels 16, 18 often look very similar from their exterior and are interchangeable with respect to the manifold. Under the present manifold assembly, the position of the first and second channels 16, 18 relative to the manifold 14 is determined by the geometry of the mating of the manifold ends 34, 48 of the first and second channels 16, 18 and the first and second channel ports 26, 28 of the manifold 14. As described above, the cross-sectional geometry of the manifold end 48 of the second channel 18 is different than the cross-sectional geometry of the manifold end 34 of the first channel 16. Thus, the manifold end 48 of each second channel 18 will mate only with the second channel port 28 disposed within the manifold 14 and the manifold end 34 of each first channel 16 will mate only with the first channel port 26 disposed within the manifold 14.

In operation, fluid enters the heat exchanger system 100 through the inlet port 30 in the manifold assembly 10. Fluid flows from the inlet port 30 into the interior cavity 20 of the manifold 14, through the first and second passages 16, 18 and into the heat exchanger 12. The particular flow pattern of the fluid is determined in part by the flow profiles of the first and second flow channels 16, 18. Thus, the first and second channels 16, 18 are positioned relative to the manifold 14 and the heat exchanger 12 such that the flow profile of a particular channel results in a desired fluid flow in the aligned regions of the heat exchanger 12. Thus, manifold assembly 10 generates a selectively selected non-uniform fluid flow into heat exchanger 12 that is subject to a non-uniform cross flow (cross flow), thereby improving the performance of heat exchanger 12.

An embodiment of a method for manufacturing the manifold assembly 10 shown in fig. 1 is also disclosed. Although the method includes various steps, it should be noted that the order of the steps is not fixed and the steps may be performed in a variety of different orders. Additionally, in some embodiments, some steps may be deleted or combined into a single step. In step (a), a manifold 14 is provided having: an inner cavity 20; one or more first channel ports 26, each first channel port having a first port geometry; and one or more second channel ports 28, each second channel port having a second port geometry. The second port geometry is different from the first port geometry. In step (b), one or more first channels 16 are provided, each first channel having a manifold end, a chamber end, and a first flow profile. The manifold end of each first channel 16 mates with each first channel port 26. In step (c), one or more second channels 18 are provided, each having a manifold end, a chamber end, and a second flow profile. The manifold end of each second channel 18 mates with each second channel port 28. In step (d), mating the manifold end of each first channel 16 with one of the first channel ports 26 disposed within the manifold; and the manifold end of each second channel 18 is mated with one of the second channel ports 28 disposed within the manifold to fluidly couple the manifold lumen 20 to the first channel 16 and the second channel 18.

While various embodiments of the invention have been disclosed, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.

Claims (9)

1. A manifold assembly for distributing a fluid to a heat exchanger, the manifold assembly comprising:

a plurality of channels including one or more first channels and one or more second channels, wherein each of the first channels has a first flow profile and has a manifold end with a first cross-sectional geometry, and each of the second channels has a second flow profile and has a manifold end with a second cross-sectional geometry, wherein the first cross-sectional geometry is different from the second cross-sectional geometry; and a manifold having an internal cavity, an entry port, one or more first channel ports, and one or more second channel ports, wherein each of the first channel ports is configured to mate with the manifold end of the first channel and each of the second channel ports is configured to mate with the manifold end of the second channel;

whereinThe manifold end of each of the first channels has a circular first cross-sectional geometry with an outer diameter, and the manifold end of each of the second channels has a circular second cross-sectional geometry with an outer diameter, and the outer diameter of the manifold end of the second channel is smaller than the outer diameter of the manifold end of the first channel.

2. The manifold assembly of claim 1, wherein the first channel port has an inner diameter and the second channel port has an inner diameter, and wherein the outer diameter of the manifold end of the first channel is greater than the inner diameter of each of the second channel ports.

3. The manifold assembly of claim 1, wherein the manifold end of each of the first channels is configured to be received within one of the first channel ports of the manifold.

4. The manifold assembly of claim 1, wherein the manifold end of each of the second channels is configured to be received within one of the second channel ports of the manifold.

5. The manifold assembly of claim 1, wherein the first flow profile is different than the second flow profile.

6. A method for manufacturing a manifold assembly for distributing fluid to a heat exchanger, the method comprising the steps of:

providing a manifold having: an inner lumen, one or more first channel ports, and one or more second channel ports, wherein each of the first channel ports has a first port geometry and each of the second channel ports has a second port geometry; wherein the second port geometry is different from the first port geometry;

providing one or more first channels, each of said first channels having a manifold end and a chamber end, and each of said first channels having a first flow profile, wherein said manifold end of each of said first channels mates with each of said first channel ports;

providing one or more second channels, each of the second channels having a manifold end and a chamber end, and each of the second channels having a second flow profile, wherein the manifold end of each of the second channels mates with each of the second channel ports; and

mating the manifold end of each of the first channels with one of the first channel ports disposed within the manifold; and mating the manifold end of each of the second channels with one of the second channel ports disposed within the manifold; thereby fluidly coupling the internal cavity of the manifold to the first and second channels.

7. The method of claim 6, wherein the manifold end of each of the first channels has a circular cross-section with a first outer diameter, the manifold end of each of the second channels has a circular cross-section with a second outer diameter, and the first outer diameter is greater than the second outer diameter.

8. The method of claim 7, wherein the manifold end of each of the first channels mates with one of the first channel ports by insertion into the first channel port, and the manifold end of each of the second channels mates with one of the second channel ports by insertion into the second channel port.

9. The method of claim 6, wherein the first flow profile is greater than the second flow profile.